A Ten Year Case Study Using Dust Control Fans At A Ship Building Site

In today’s episode of the Dust Safety Science podcast, Jordan Newton, CEO at SonicAire based out of Winston-Salem, North Carolina, discusses a ten year case study using dust control fans at a ship building site.

Jordan recently presented a fascinating case study at the 2024 Global Dust Safety Conference held in March. This presentation focused on the implementation of SonicAire Control fans, a topic that has generated considerable discussion among dust safety professionals and through community help desks. Jordan has been a guest on the podcast before, first in Episode #66, where he discussed how SonicAire fans prevent dust accumulation. This discussion was followed by Episode #164, which was a crossover.

Over the years, Jordan has frequently presented at the Dust Safety Conference, most notably sharing a ten-year case study on the use of SonicAire fans at a single site. This study is particularly valuable because it provides robust data on how the technology has evolved, the modifications that have been made, and the challenges that have been addressed. Today, Jordan talks about what SonicAire dust control fans are, why Viking has integrated them into their systems, and the promising developments forthcoming from SonicAire.

How Does SonicAire Support Safety in Facilities?

Jordan explained that for anyone handling or processing materials where dust is a byproduct—such as grinding, chopping, crushing, moving, or transporting—dust management becomes essential. When dust escapes into the atmosphere, it poses various challenges. Many processing facilities deal with fugitive dust, which is dust that escapes containment and disperses into the environment, often accumulating in overhead spaces.

To address this issue, companies are advised to capture as much dust as possible to prevent it from entering the atmosphere. SonicAire has a solution that involves the use of what is referred to as “barrier air” or an overhead air curtain, which effectively creates a barrier that prevents dust from rising. This system ensures that dust falls back to the floor, where it can be easily cleaned up during routine housekeeping, thus avoiding the need for costly and labor-intensive overhead cleaning.

This containment is facilitated by a high-velocity stream of air from fans that oscillate and rotate 360 degrees continuously. The air flow encourages dust particles to agglomerate, or clump together, making them heavier and faster to settle. This process might initially seem counterintuitive, as using a fan could ostensibly disperse dust further. However, it effectively speeds up dust clearance from the air and prevents it from lingering.

Why Did Viking Yachts Come to SonicAire?

In 2014, Jeff Staub, the engineering manager at a particular company, reached out after noticing a feature in an industrial hygiene magazine. The company was grappling with a dust issue and was considering technological solutions to minimize manual cleaning in hard-to-reach areas. However, after initial discussions, communication dwindled, and for a few years, there was little progress or engagement.

The issue regained urgency when an insurance inspector visited the company and highlighted the severity of the dust problem, stressing that immediate action was necessary. This prompted Staub to establish a definitive program to address the dust control effectively. Following this intervention, the company reinitiated contact, and the collaboration to tackle the dust issue began in earnest.

What Did The Original Installation Look Like?

Jordan explained that initially, the focus was on Building 2N, where boat hulls undergo finishing and processing. These fiberglass hulls, fresh from molds, require extensive hand-finishing using sanders, grinders, and polishers, making dust capture challenging. This area was notorious for substantial amounts of fugitive fiberglass dust.

To address this, a fan layout was designed for the largely unobstructed space of Building 2N. Despite the open area, numerous horizontal surfaces in the upper sections—such as beams, joists, conduits, and HVAC equipment—tended to accumulate dust quickly. The introduction of strategically placed fans made a noticeable difference in dust levels, which was initially met with enthusiasm.

However, the noise generated by the first generation of two-horsepower fans presented a new challenge. These fans, while effective, produced a sound likened to a siren, which was not only loud but had a particularly disruptive tone. Despite being within OSHA’s noise regulation of 90dB, the acoustic quality proved bothersome to employees working under these conditions daily, leading some to turn off the fans to avoid the noise.

Jeff Staub noted the noise concerns and suggested an alternative application for the fans in a less noise-sensitive area. This led to the installation of the fans in the router room, a space housing a large five-axis router used for creating molds for fiberglass. This area, with fewer employees, suited the louder fans better. In 2019, the installation of these fans in the router room effectively managed the dust accumulation in the ceiling areas, meeting the approval of the staff working there.

What Was The Solution?

Late in 2019 and into early 2020, a new generation of fans was introduced, known as the Pro 200. Although still operating at two horsepower, the design of these fans was completely overhauled to optimize airflow, resulting in a significant reduction of noise. The redesign effectively eliminated 75% of the overall sound volume and 98% of the tonal noise, which had been particularly bothersome. This change made the sound emitted by the fans more akin to white noise, enhancing the work environment as it became more tolerable and less intrusive.

This improvement was well received, with customers noting the marked decrease in noise levels—a stark contrast to the earlier feedback regarding the disruptive noise of the previous fan models. Following these advancements, the facilities that initially had the louder fans underwent retrofits to incorporate the new, quieter models. These upgraded fans now operate continuously without generating noise complaints from employees, who find them unobtrusive compared to the ongoing sound of sanders and grinders in the workspace.

The success of the fan redesign opened further opportunities for collaboration with Jeff. The focus shifted to addressing dust control in their extensive wood shop in New Jersey, where all interior components such as cabinets, trims, and moldings are crafted. Despite having traditional dust collectors around major dust-generating equipment like table saws and routers, fugitive dust remained an issue.

The wood shop, characterized by a congested layout with numerous obstructions such as ductwork and overhead lights, posed challenges for placing the fans. The initial plan had to be adapted to the space constraints, requiring strategic placement of fans to effectively manage dust accumulation. Eventually, five or six fans were installed in key areas to optimize dust control, allowing for continuous operation without the need for manual cleaning. This setup enabled easy maintenance, as workers could simply use dust mops to clean the floors, significantly simplifying the cleanup process in this busy production environment.

How Is The Dislodged Dust Cleaned Up?

If dust does not accumulate all the way to the floor but remains at a lower, easily reachable level, using vacuums can be an effective cleaning method. However, for many facilities, especially those with concrete or select floors, a simple dust mop suffices. This method is akin to using a gym floor dust mop, similar to what one might remember from school gyms. It allows for quick coverage of large areas and is part of daily cleaning routines.

In truth, only a small percentage of dust ever reached the ceiling before fans were introduced; most of it would naturally settle on the floor. Thus, the implementation of fans has not significantly increased the amount of dust on the floor—perhaps only adding about 10% more than what existed before their use. Continued regular maintenance and housekeeping at floor level effectively manage dust accumulation, maintaining clean and safe conditions within these environments.

What Was The Process After 2020?

The sound issue and the woodshop dust control were successfully resolved. Subsequently, Jeff revisited the router room and expressed appreciation for the performance of the fans, but pointed out the inconvenience of manually operating them based on varying process requirements. This was not an isolated concern, as many other customers faced similar challenges with processes that required intermittent fan operation to avoid disrupting sensitive work.

To address this, a solution was devised to synchronize fan operation with process activities, adhering to NFPA recommendations that fans should run concurrently with operational processes whenever feasible. A control panel, known as the Command Series, was developed, featuring a mechanism called the Epic Loop. This system uses a signal from the operational process to interlock the fans, allowing them to be programmed to either run with the process or activate when the process ceases.

This innovation marked a significant shift from a managed to an engineered solution. Initially, the setup in the router room required manual intervention, depending on operators to turn the fans on and off as needed. However, with the new control panel, fan operation could be automated to ensure they ran consistently and effectively, preventing the accumulation of dust clouds. The guidance is clear: if a dust cloud is visible while the fans are operating, it indicates insufficient frequency of use, underscoring the need for continuous and routine operation once the fans are integrated into the system.

Were There Any More Steps In The Process?

As Jeff successfully integrated the fans with the operational processes, he noticed a new challenge. The fans’ adjustable sweep was initially a boon, efficiently clearing dust from atop nearby equipment. However, their placement on one side of the room—intended to avoid interference with an overhead router—caused an unintended consequence. When the fans rotated toward the wall, the airflow would stir up dust from the floor.

To address this, Jeff proposed adjusting the air velocity when the fans faced the wall. This was a novel issue for the team, prompting a return to the drawing board to explore possible adjustments through sensors and controls. The solution developed was a “zone control” system using proximity sensors, allowing for modulation of fan speed based on the fan’s orientation within the room. At Jeff’s facility, the fans now operate at 50% speed when sweeping near the wall, effectively preventing dust disturbance while maintaining necessary airflow to keep the wall clean.

Once the fans rotate away from the wall into more open areas, they resume full speed to ensure thorough coverage. This “zone control” mechanism, implemented in 2023, represented a significant innovation, addressing a specific operational challenge and enhancing overall dust management.

Alongside this technological advancement, the team expanded its service offerings. A dedicated service team was established to provide installation services, preventative maintenance, and comprehensive support, ensuring that customers not only receive a superior product but also benefit from end-to-end service and ongoing care. This expansion into service provision marked a significant enhancement in the company’s portfolio, aimed at delivering a more effective and holistic solution to dust control.

What’s Next For SonicAire?

Several projects are currently underway, including the launch of the company’s Class II Division 1 rated fan, a significant achievement following three to four years of collaboration with UL. This fan is the first to receive UL certification for this specific class, marking a milestone in dust control technology. The development process involved extensive design modifications, updates, and negotiations.

Additionally, the upcoming NFPA 660 edition includes revisions that the company advocated for, which appear likely to remain in the final publication. Previously, the regulations specifically recommended the use of fans for overhead processes. However, the company proposed expanding this to include “hard to reach” areas, not just overhead spaces. This change is particularly relevant in scenarios involving conveyors within fenced areas, where dust builds up at floor level, necessitating halts in production for cleaning. This led to the development of a new fan model tailored for sweeping dust at floor level, designed to move dust from fenced areas for regular collection during routine housekeeping.

Furthermore, the company is developing a three-horsepower fan, an upgrade from the current two-horsepower models. This new model is designed to address the challenges of moving finer, denser dust particles that require higher air velocity for effective displacement. The design changes include adjustments to the operational speeds—both rotational and vertical movements—aiming to maximize the coverage and efficiency of dust control in a variety of industrial environments. This innovation reflects the company’s ongoing commitment to adapting and enhancing their product line to meet diverse industry needs.

Conclusion

SonicAire’s ongoing commitment to innovation and customer-focused solutions continues to advance industrial safety standards. The company’s proactive approach to addressing complex dust control challenges not only improves workplace safety but also enhances operational efficiencies across various industries.

With each technological advancement and strategic initiative, SonicAire is setting new benchmarks in dust management, ensuring safer and cleaner working environments for its clients. As they move forward, the anticipation of what they will introduce next keeps the industry watching and waiting for the next big leap in dust control technology.

If you would like to discuss further, leave your thoughts in the comments section below. You can also reach Jordan Newton directly:

Website: https://www.sonicaire.com/

LinkedIn: https://www.linkedin.com/in/jordan-newton-p-e-8100867/

Email: [email protected]

If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.